Rotor core, rotor, motor, manufacturing method of rotor core, and manufacturing method of rotor

ABSTRACT

A rotor core includes laminate steel plates extending in a radial direction with respect to a central axis. The laminate steel plates each include a base portion on a radially outer side of the central axis, and pieces separately disposed on a radially outer side of the base portion with penetrating portions therebetween, and arranged side by side at predetermined intervals in a circumferential direction. The laminate steel plates are laminated in an axial direction. The laminated steel plate at an upper end in the axial direction includes at least one of an outward projection extending radially outward from an outer edge portion of the base portion and an inward projection extending radially inward from an inner edge portion of the piece, and the laminated steel plate at a lower end in the axial direction includes an intervening portion between the base portion and the piece portion.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a rotor core, a rotor, a motor, amanufacturing method of a rotor core, and a manufacturing method of arotor.

2. Description of the Related Art

Conventionally, a motor in which a rotor having a magnet and a shaft isdisposed on a radially inner side of an annular stator having anexcitation coil has been widely known.

A conventional rotor of an electric motor has an electromagnetic steelplate, magnetic pole pieces separated radially outward from a main bodyof the electromagnetic steel plate, and permanent magnets embedded in aradially inner side of the magnetic pole pieces.

SUMMARY OF THE INVENTION

According to an example embodiment of the present disclosure, a rotorcore includes a laminate steel plate extending in a radial directionwith respect to a central axis. The laminate steel plate includes a baseportion positioned on a radially outer side of the central axis, and aplurality of pieces separately disposed on a radially outer side of thebase portion with penetrating portions therebetween, and arranged sideby side at predetermined intervals in a circumferential direction. Inthe rotor core, the plurality of laminate steel plates are laminated inan axial direction, the laminated steel plate disposed at an upper endin the axial direction includes at least one of an outward projectionextending radially outward from an outer edge portion of the baseportion and an inward projection extending radially inward from an inneredge portion of the piece, and the laminated steel plate disposed at alower end in the axial direction includes an intervening portion thatintervenes between the base portion and the piece.

According to an example embodiment of the present disclosure, a rotorincludes the rotor core of the above configuration, and a plurality ofmagnets disposed in the penetrating portions of the rotor core. Therotor core includes a plurality of space portions which are disposedbetween the penetrating portions adjacent to each other in thecircumferential direction, and penetrate the rotor core in the axialdirection.

According to an example embodiment of the present disclosure, a motorincludes the rotor of the above configuration.

A manufacturing method of a rotor core of an example embodiment of thepresent disclosure is a manufacturing method of a rotor core in which aplurality of laminate steel plates extending in a radial direction withrespect to a central axis are laminated in an axial direction, themethod including laminating divided laminate steel plates in the axialdirection, each of the divided laminate steel plates including a baseportion positioned on a radially outer side of the central axis, and aplurality of pieces separately disposed on a radially outer side of thebase portion with penetrating portions therebetween, and arranged atpredetermined intervals in a circumferential direction; laminating aconnected laminate steel plate having the base portion and the piecesconnected via connecting portions at an upper end in the axial directionof the divided laminate steel plates that are laminated, laminating anintervening laminate steel plate including intervening portions thatintervene between the base portion and the pieces at a lower end in theaxial direction of the divided laminate steel plates that are laminated,and cutting the connecting portions with a cutter by inserting thecutter into the penetrating portions.

A manufacturing method of a rotor according to an example embodiment ofthe present disclosure includes cutting the connecting portion with acutter by using the rotor core produced by the above-describedmanufacturing method of the rotor core, and then removing the cutterfrom the penetrating portion and inserting a magnet into the penetratingportion.

The above and other elements, features, steps, characteristics andadvantages of the present disclosure will become more apparent from thefollowing detailed description of the example embodiments with referenceto the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a motor according to a first example embodimentof the present disclosure.

FIG. 2 is a perspective view of a rotor core of the motor according tothe first example embodiment of the present disclosure as viewed fromabove.

FIG. 3 is a perspective view of the rotor core of the motor according tothe first example embodiment of the present disclosure as viewed fromthe below.

FIG. 4 is a plan view of a first laminate steel plate of the rotor coreaccording to the first example embodiment of the present disclosure.

FIG. 5 is a plan view of a second laminate steel plate of the rotor coreaccording to the first example embodiment of the present disclosure.

FIG. 6 is a perspective view of a rotor core of a motor according to asecond example embodiment of the present disclosure as viewed fromabove.

FIG. 7 is a perspective view of the rotor core of the motor according tothe second example embodiment of the present disclosure as viewed frombelow.

FIG. 8 is a plan view of a connected laminate steel plate of the rotorcore according to the second example embodiment of the presentdisclosure.

FIG. 9 is a partial enlarged plan view of a connected laminate steelplate of a rotor core according to a third example embodiment of thepresent disclosure.

FIG. 10 is a perspective view showing an example of a cutting deviceused in a manufacturing method of the rotor core according to the thirdexample embodiment of the present disclosure.

FIG. 11 is a partially enlarged plan view showing an example of acutting tool used in the manufacturing method of the rotor coreaccording to the third example embodiment of the present disclosure.

FIG. 12 is a partial enlarged plan view of a connected laminate steelplate showing a first example of a cutting process in the manufacturingmethod of the rotor core according to the third example embodiment ofthe present disclosure.

FIG. 13 is a plan view of a connected laminate steel plate showing asecond example of the cutting process in the manufacturing method of therotor core according to the third example embodiment of the presentdisclosure.

FIG. 14 is a plan view of a connected laminate steel plate showing athird example of the cutting process in the manufacturing method of therotor core according to the third example embodiment of the presentdisclosure.

FIG. 15 is a perspective view of a rotor core of a motor according to afourth example embodiment of the present disclosure viewed from above.

FIG. 16 is a perspective view of the rotor core of the motor accordingto the fourth example embodiment of the present disclosure as viewedfrom the below.

FIG. 17 is a plan view of a connected laminate steel plate of the rotorcore according to the fourth example embodiment of the presentdisclosure.

FIG. 18 is a perspective view of a rotor core of a motor according to afifth example embodiment of the present disclosure as viewed from above.

FIG. 19 is a perspective view of the rotor core of the motor accordingto the fifth example embodiment of the present disclosure as viewed frombelow.

FIG. 20 is a plan view of a connected laminate steel plate of the rotorcore according to the fifth example embodiment of the presentdisclosure.

FIG. 21 is a perspective view of a first modification of the rotor coreaccording to the fifth example embodiment of the present disclosure asseen from above.

FIG. 22 is a perspective view of the first modification of the rotorcore according to the fifth example embodiment of the present disclosureas seen from the below.

FIG. 23 is a longitudinal end view showing a first step of amanufacturing method of a second modification of the rotor coreaccording to the fifth example embodiment of the present disclosure.

FIG. 24 is a longitudinal end view showing a second step of themanufacturing method of the rotor core according to the secondmodification of the fifth example embodiment of the present disclosure.

FIG. 25 is a longitudinal end view showing a third step of themanufacturing method of the second modification of the rotor coreaccording to the fifth example embodiment of the present disclosure.

FIG. 26 is a perspective view of a rotor core of a motor according to asixth example embodiment of the present disclosure as seen from above.

FIG. 27 is a perspective view of the rotor core of the motor accordingto the sixth example embodiment of the present disclosure as viewed frombelow.

FIG. 28 is a plan view of a first laminate steel plate of the rotor coreaccording to the sixth example embodiment of the present disclosure.

FIG. 29 is a plan view of a second laminate steel plate of the rotorcore according to the sixth example embodiment of the presentdisclosure.

FIG. 30 is a perspective view of a rotor of a motor according to aseventh example embodiment of the present disclosure.

FIG. 31 is a plan view of the rotor of the motor according to theseventh example embodiment of the present disclosure.

FIG. 32 is a longitudinal end view showing an example first step of amanufacturing method of a second modification of the rotor coreaccording to the fifth example embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, example embodiments of the present disclosure will bedescribed in detail with reference to the drawings. In thespecification, a direction in which a rotational axis of a motor extendsis simply referred to as an “axial direction,” a direction orthogonal tothe rotational axis centering around the rotational axis of the motor issimply referred to as a “radial direction,” and a direction along an arccentering around the rotational axis of the motor is simply referred toas a “circumferential direction.” The central axis of the rotor corecoincides with the rotational axis of the motor. Also, in thespecification, for the sake of convenience of explanation, the axialdirection is defined as a vertical direction, and a shape and apositional relationship of each part will be described with a depthdirection of the sheet of FIG. 1 serving as the vertical direction ofthe rotor core, the rotor, and the motor. It should be noted that thedefinition in the vertical direction does not limit the direction whenthe motor is used. Also, in the specification, an end view parallel tothe axial direction is referred to as a “longitudinal end view.” Inaddition, the terms “parallel” and “vertical” used in the specificationdo not mean technically parallel or vertical, but include substantiallyparallel and substantially vertical.

An overall configuration of a motor according to a first preferredembodiment of the present invention will be described. FIG. 1 is a planview of a motor according to an preferred embodiment of the presentinvention. The motor 1 shown in FIG. 1 has a stator 2 and a rotor 3.

The stator 2 has, for example, a cylindrical or substantiallycylindrical shape extending in the axial direction. The stator 2 isdisposed with a predetermined gap provided radially outside the rotor 3.The stator 2 has a stator core 21, an insulator 22, and a coil 23.

The stator core 21 has a tubular or substantially tubular shapeextending in the axial direction. The stator core 21 is formed bylaminating a plurality of magnetic steel plates in the axial direction.The stator core 21 has a core back 21 a and teeth (not shown). The coreback 21 a has an annular or substantially annular shape. The teethextend radially inward from an inner circumferential surface of the coreback 21 a. A plurality of teeth are arranged side by side atpredetermined intervals in the circumferential direction.

The insulator 22 is provided to surround an outer surface of a tooth.The insulator 22 is disposed between the stator core 21 and the coil 23.The insulator 22 is made of, for example, an electrically insulatingmember made of a synthetic resin. The coil 23 is formed by winding aconductive wire around an outer circumference of the insulator 22.

The rotor 3 has a cylindrical or substantially cylindrical shapeextending in the axial direction. The rotor 3 is positioned with apredetermined gap provided radially inside the stator 2. The rotor 3 hasa shaft 31, a rotor core 40, magnets 32, and space portions 33 or resinportions 34. The space portions 33 have column portions 33 a and outerperipheral portions 33 b.

The shaft 31 is a rotational axis of the motor 1. The shaft 31 has acolumnar or substantially columnar shape extending in a verticaldirection. The shaft 31 is inserted into an upper bearing and a lowerbearing (both not shown) provided on an upper side and a lower side ofthe rotor 3 and is rotatably supported thereon. The rotor 3 rotatesaround the shaft 31 extending in the vertical direction.

The rotor core 40 has a cylindrical or substantially cylindrical shapeextending in the axial direction. The shaft 31 is inserted into holeportions 41 d and 42 d positioned at a radially central portion of therotor core 40. The central axis of the rotor core 40 coincides with theshaft 31 of the motor 1. The rotor core 40 is formed by laminating, forexample, a plurality of magnetic steel plates in the axial direction.Details of the rotor core 40 will be described later.

The magnet 32 is disposed radially inside an outer edge portion of therotor core 40. A plurality of magnets 32 are arranged side by side atpredetermined intervals in the circumferential direction. For example,eight magnets 32 are provided. The magnet 32 is a rectangularparallelepiped body having a substantially rectangular bottom surfaceand extending in the axial direction. An axial length of the magnet 32substantially coincides with an axial length of the rotor core 40. Themagnet 32 is supported by the rotor core 40.

The column portions 33 a are provided between the magnets 32 adjacent toeach other in the circumferential direction. For example, when there areeight magnets 32, the column portions 33 a are provided at eight places.The column portion 33 a is a space of a quadrangular column orsubstantially quadrangular column shape whose bottom surface has atrapezoidal or substantially trapezoidal shape and extends in the axialdirection. The column portion 33 a penetrates the rotor core 40 in theaxial direction. By providing the column portion 33 a, it is possible tomore effectively utilize magnetic flux of the magnet 32 in the rotor 3.

The outer peripheral portions 33 b are provided on outer sides in theradial direction of the column portions 33 a. The outer peripheralportions 33 b are provided at eight locations. The outer peripheralportions 33 b have substantially semicircular bottom surfaces and extendin the axial direction.

The resin portions 34 are provided in the space portions 33. The resinportions 34 are provided by pouring a synthetic resin, an adhesive, etc.into a space portion 33 surrounded by an outer circumferential surfaceof the rotor core 40 and an inner circumferential surface of a metalmold (not shown) disposed radially outside the rotor core 40 at an outeredge portion of the rotor 3. As a result, the resin portions 34 play arole as a flux barrier.

Subsequently, a detailed configuration of the rotor core 40 will bedescribed. FIG. 2 is a perspective view of the rotor core of the motor 1according to the first preferred embodiment of the present invention asviewed from above. FIG. 3 is a perspective view of the rotor core of themotor 1 according to the first preferred embodiment of the presentinvention as viewed from below. FIG. 4 is a plan view of a firstlaminate steel plate of the rotor core according to the first preferredembodiment of the present invention. FIG. 5 is a plan view of a secondlaminate steel plate of the rotor core according to the first preferredembodiment of the present invention.

The rotor core 40 shown in FIGS. 2 and 3 has first laminate steel plates41 and second laminate steel plates 42. Each of the first laminate steelplates 41 and the second laminate steel plates 42 expands in the radialdirection with respect to the central axis of the rotor core 40.

The first laminate steel plate 41 shown in FIG. 4 has a first baseportion 41 a, a penetrating portion 41 b, and a piece portion 41 c.

The first base portion 41 a is positioned on a radially outer side ofthe central axis. An outer shape of the first base portion 41 a issubstantially octagonal. At the radially central portion of the firstbase portion 41 a, there is a hole portion 41 d through which the shaft31 penetrates in the axial direction.

The penetrating portion 41 b is provided on a radially outer side ofeach of eight edges of an outer edge portion 41 w of the first baseportion 41 a. The penetrating portion 41 b is formed as a gap betweenthe first base portion 41 a and the piece portion 41 c. The magnets 32are provided one by one in the eight penetrating portions 41 b,respectively (see FIG. 1).

The piece portion 41 c is separately disposed on a radially outer sideof the first base portion 41 a with the penetrating portion 41 btherebetween. The plurality of piece portions 41 c are disposed atpredetermined intervals in the circumferential direction. For example,eight piece portions 41 c are provided radially outside the eight edgeson the outer periphery of the first base portion 41 a, respectively. Thecenter of the piece portion 41 c is shifted radially outward from theaxis of the shaft 31 in its shape in a plan view, and the piece portion41 c is in a semicircular or substantially semicircular shape which hasan arc with a radius smaller than the radius of the rotor 3 and astraight portion corresponding to a string positioned on a radiallyinner side of the arc. The straight portion on the radially inner sideof the piece portion 41 c is substantially parallel to the outer edgeportion 41 w of the first base portion 41 a.

The first base portion 41 a has protruding portions 41 e. The protrudingportions 41 e are provided in angular regions with respect to thecentral axis between the piece portions 41 c adjacent to each other inthe circumferential direction. That is, the protruding portions 41 e areprovided in fan-shaped regions surrounded by circumferentially opposedend portions of the circumferentially adjacent piece portions 41 c andthe central axis, respectively. In other words, the protruding portions41 e are provided on the column portions 33 a of the rotor 3. Anpreferred example of the fan-shaped angular region with respect to thecentral axis between the circumferentially adjacent piece portions 41 cis illustrated with a one-dot chain line in FIG. 4.

The protruding portion 41 e protrudes radially outward from the outeredge portion 41 w of the first base portion 41 a. When the first baseportion 41 a is polygonal, the protruding portion 41 e protrudesradially outward from each apex of the first base portion 41 a. Aprotruding length of the protruding portion 41 e is shorter than a widthof the penetrating portion 41 b in the radial direction. Since the firstbase portion 41 a has the protruding portion 41 e, when the magnet 32 isinserted between the first base portion 41 a and the piece portion 41 c,that is, the penetrating portion 41 b, circumferential end portions ofthe magnet 32 can be brought into contact with the protruding portions41 e. Accordingly, it is possible to perform the positioning of themagnet 32 in the circumferential direction.

The second laminate steel plate 42 shown in FIG. 5 has a second baseportion 42 a, penetrating portions 42 b, and annular portions 42 c.

The second base portion 42 a is positioned on a radially outer side ofthe central axis. An outer shape of the second base portion 42 a issubstantially octagonal. The outer shape of the second base portion 42 ais substantially the same as the outer shape of the first base portion41 a. In a central portion of the second base portion 42 a in the radialdirection, there is a hole portion 42 d through which the shaft 31penetrates in the axial direction.

The penetrating portion 42 b is provided on a radially outer side ofeach of eight edges on an outer periphery of the second base portion 42a. The penetrating portion 42 b is formed as a gap between the secondbase portion 42 a and a large diameter portion 42 f of the annularportion 42 c which will be described later. The magnets 32 are providedone by one in eight penetrating portions 42 b, respectively (see FIG.1).

The annular portion 42 c is separately disposed on a radially outer sideof the second base portion 42 a with the penetrating portion 42 btherebetween. The annular portion 42 c extends in the circumferentialdirection. The annular portion 42 c has a shape similar to a shapeobtained by connecting the eight piece portions 41 c of the firstlaminate steel plate 41 in an annular or substantially annular shape.

The annular portion 42 c has a large diameter portion 42 f and a smalldiameter portion 42 g which have different outer diameters. In theannular portion 42 c, the large diameter portion 42 f and the smalldiameter portion 42 g are alternately arranged in the circumferentialdirection. According to this configuration, magnetic saturation islikely to occur in the small diameter portion 42 g. Therefore, it ispossible to efficiently guide the magnetic flux, so that and generationof the magnetic flux loop inside the rotor core 40 can be suppressed.

In the axial direction, the large diameter portion 42 f is disposed atthe same position as the piece portion 41 of the first laminate steelplate 41. The large diameter portion 42 f has a cutout circular orsubstantially cutout circular shape similar to that of the piece portion41 c in its shape in a plan view. The large diameter portion 42 f isprovided on a radially outer side of each of eight edges of the outerperiphery of the second base portion 42 a at eight positions, similarlyto the piece portion 41 c. A straight portion on a radially inner sideof the large diameter portion 42 f is substantially parallel to a sideof the outer periphery of the second base portion 42 a. An outerdiameter of the large diameter portion 42 f is larger than an outerdiameter of the small diameter portion 42 g.

In the axial direction, the small diameter portion 42 g is disposed atthe same position as a region between the piece portions 41 adjacent toeach other in the circumferential direction of the first laminate steelplate 41. The small diameter portion 42 g has a long plate orsubstantially long plate shape connecting the large diameter portions 42f adjacent in the circumferential direction in its shape in a plan view.The small diameter portion 42 g connects end portions of two largediameter portions 42 f to each other. The outer diameter of the smalldiameter portion 42 g is smaller than the outer diameter of the largediameter portion 42 f.

The small diameter portion 42 g has projections 42 h. The projections 42h extend radially inward from an inner circumferential surface of thesmall diameter portion 42 g. According to this configuration, a strengthof the annular portion 42 c can be improved. Further, when the magnet 32is inserted between the second base portion 42 a and the annular portion42 c, that is, the penetrating portion 42 b, circumferential endportions of the magnet 32 can be brought into contact with theprojections 42 h. In this way, it is possible to perform positioning ofthe magnet 32 in the circumferential direction. Also, a radial length ofthe projection 42 h is shorter than a radial width of the penetratingportion 42 b.

For example, two projections 42 h are provided for one small diameterportion 42 g. The two projections 42 h provided in the one smalldiameter portion 42 g are arranged in a circumferentially separatedmanner. According to this configuration, it is possible to widely usethe region between the two projections 42 h as a flux barrier.Therefore, it is possible to more effectively utilize the magnetic fluxof the magnet. The number of the projections 42 h is not limited to two,and may be one or three or more.

The second base portion 42 a has protruding portions 42 e. Theprotruding portion 42 e are provided in angular regions with respect tothe central axis where the small diameter portions 42 g are positioned.In the case where the second base portion 42 a is polygonal, theprotruding portion 42 e protrudes radially outward from each apex of thesecond base portion 42 a. That is, the protruding portion 42 e isprovided in a fan-shaped region surrounded by both circumferential endportions of the small diameter portion 42 g and the central axis. Inother words, the protruding portion 42 e is provided on the columnportion 33 a of the rotor 3. An example of the fan-shaped angular regionwith respect to the central axis where the small diameter portion 42 gis positioned is illustrated with a one-dot chain line in FIG. 5.

In addition, as described above, the small diameter portion 42 g isdisposed at the same position as the region between thecircumferentially adjacent piece portions 41 c of the first laminatesteel plate 41 in the axial direction. Therefore, as far as the rotorcore 40 is concerned, the protruding portion 42 e is provided in theangular region with respect to the central axis between the pieceportions 41 c adjacent to each other in the circumferential direction.

The protruding portion 42 e protrudes radially outward from an outeredge portion 42 w of the second base portion 42 a. A tip portion of theprotruding portion 42 e faces the radially inner side of the smalldiameter portion 42 g. The protruding portion 42 e is disposed in aregion between the two projections 42 h with respect to thecircumferential direction. A protruding length of the protruding portion42 e is shorter than a width of the penetrating portion 42 b in theradial direction. In addition, the protruding portion 42 e does not comeinto contact with the two projections 42 h. Since the second baseportion 42 a has the protruding portion 42 e, when the magnet 32 isinserted between the second base portion 42 a and the annular portion 42c, that is, the penetrating portion 42 b, the circumferential endportions of the magnet 32 can be brought into contact with theprotruding portions 42 e. Accordingly, it is possible to perform thepositioning of the magnet 32 in the circumferential direction.

The rotor core 40 shown in FIGS. 2 and 3 is formed by laminating aplurality of first laminate steel plates 41 having the above structureand at least one second laminate steel plate 42 having the abovestructure in the axial direction. At this time, the piece portion 41 cof the first laminate steel plate 41 and the large diameter portion 42 fof the annular portion 42 c of the second laminate steel plate 42overlap in the axial direction, and the first laminate steel plate 41and the second laminate steel plate 42 are laminated at a position wheretheir outer peripheral edges are partially aligned. The first laminatesteel plate 41 and the second laminate steel plate 42 are fixed, forexample, by caulking or the like.

According to this configuration, there is no region of a steel plateover the entire region in the circumferential direction between thefirst base portion 41 a of the first laminate steel plate 41 and thepiece portion 41 c and between the second base portion 42 a and theannular portion 42 c of the second laminate steel plate 42. In this way,a flux barrier such as an air layer can be provided between the firstbase portion 41 a and the piece portion 41 c and between the second baseportion 42 a and the annular portion 42 c. Therefore, it is possible tomore effectively utilize the magnetic flux of the magnet 32.

Since the number of the second laminate steel plates 42 is smaller thanthe number of the first laminate steel plates 41, it is possible tosuppress an amount of magnetic flux flowing through the annular portion42 c of the entire rotor core 40 as compared to the case where theentire rotor core 40 is formed by the second laminate steel plates 42.Therefore, it is possible to more effectively utilize the magnetic fluxof the magnet 32 in the annular portion 42 c.

More specifically describing with respect to the laminated structure ofthe first laminate steel plates 41 and the second laminate steel plates42, for example, two pieces of second laminate steel plates 42 aredisposed at the upper end and the lower end in the axial direction ofthe rotor core 40, and a plurality of first laminate steel plates 41 aredisposed between the second laminate steel plate 42 at the upper end inthe axial direction and the second laminate steel plate 42 at the lowerend in the axial direction. According to this configuration, it ispossible to improve the strength of the rotor core 40. Further, forexample, two second laminate steel plates 42 are disposed also in amiddle portion of the plurality of first laminate steel plates laminatedin the axial direction. According to this configuration, it is possibleto further improve the strength of the rotor core 40.

The rotor core 40 may have such a configuration in which the firstlaminate steel plate 41 is disposed at each of the upper end and thelower end in the axial direction, and a plurality of second laminatesteel plates 42 are disposed between the first laminate steel plate 41at the upper end in the axial direction and the first laminate steelplate 41 at the lower end in the axial direction. In this rotor core 40,each of the upper end and the lower end in the axial direction is thefirst laminate steel plate 41. The rotor core 40 may have a structure ofa plurality of first laminate steel plates 41, one or two secondlaminate steel plates 42, and a plurality of first laminate steel plates41 in order from the top. In addition, the rotor core 40 may have astructure of a plurality of first laminate steel plates 41, one or twosecond laminate steel plates 42, a plurality of first laminate steelplates 41, one or two second laminate steel plates 42, and a pluralityof first laminate steel plates 41 in order from the top.

In the rotor core 40 where the second laminate steel plate 42 isdisposed at each of the upper end and the lower end in the axialdirection, when the axial length of the magnet 32 is shorter than theaxial length of the rotor core 40 in the rotor core 40 where the secondlaminate steel plate 42 is disposed at each of the upper end and thelower end in the axial direction, it may be considered that the annularportion 42 c of the second laminate steel plate 42 positioned at theupper end is magnetically saturated and the annular portion 42 c of thesecond laminate steel plate 42 positioned at the lower end is notmagnetically saturated. At that time, there is a possibility that adifference in distortion amount occurs between an upper end portion anda lower end portion of a back electromotive voltage waveform in the coil23 depending on presence or absence of magnetic saturation in theannular portions 42 c at the upper end and the lower end. Therefore, bynot providing the second laminate steel plate 42 at the upper end andthe lower end of the rotor core 40, distortion of the back electromotivevoltage waveform can be suppressed. Instead, by adopting a configurationin which a plurality of second laminate steel plates 42 are disposedbetween the first laminate steel plate 41 at the upper end in the axialdirection and the first laminate steel plate 41 at the lower end in theaxial direction, it is possible to prevent the first base portion 41 aand the piece portion 41 c from being separated from each other and thesecond base portion 42 a and the annular portion 42 c from beingseparated while effectively utilizing the magnetic flux of the magnet32.

In the rotor 3 of the first preferred embodiment, by pressing theannular portion 42 c of the second laminate steel plate 42 from theradially outer side, the magnet 32 can be held. Thus, the magnet can beheld without providing the resin portion 34, so that the number ofman-hours and materials can be reduced. Further, by pressing the smalldiameter portion 42 g of the annular portion 42 c, the column portion 33a can be eliminated. This makes it possible to hold the magnet morefirmly and to make more effective use of the magnetic flux.

Next, a motor according to a second preferred embodiment of the presentinvention will be described. FIG. 6 is a perspective view of a rotorcore of the motor according to the second preferred embodiment of thepresent invention as viewed from above. FIG. 7 is a perspective view ofthe rotor core of the motor according to the second preferred embodimentof the present invention as viewed from below. FIG. 8 is a plan view ofa connected laminate steel plate of the rotor core according to a secondpreferred embodiment of the present invention. Also, since a basicconfiguration of this preferred embodiment is the same as that of thefirst preferred embodiment described above, constituent elements commonto the first preferred embodiment are denoted by the same referencenumerals or the same names as before, explanation thereof may beomitted.

The rotor core 40 shown in FIGS. 6 and 7 has a connected laminate steelplate 43 in addition to the first laminate steel plate 41 and the secondlaminate steel plate 42. Similarly to the first laminate steel plate 41and the second laminate steel plate 42, the connected laminate steelplate 43 expands in the radial direction with respect to the centralaxis of the rotor core 40.

The connected laminate steel plate 43 shown in FIG. 8 has a connectedbase portion 43 a, penetrating portions 43 b, connected annular portions43 c, and connecting portions 43 k.

The connected base portion 43 a, the penetrating portion 43 b, and theconnected annular portion 43 c have the same configuration as the secondbase portion 42 a, the penetrating portion 42 b, and the annular portion42 c of the second laminate steel plate 42, respectively. That is, theconnected base portion 43 a has a hole portion 43 d and protrudingportions 43 e. The penetrating portion 43 b is formed as a gap betweenthe connected base portion 43 a and a large diameter portion 43 f of theconnected annular portion 43 c. The connected annular portion 43 c hasthe large diameter portion 43 f and a small diameter portion 43 g whichare different in outer diameter and are arranged alternately in thecircumferential direction.

In addition, in this preferred embodiment, the protruding portion 43 eof the connected laminate steel plate 43 is enlarged toward bothcircumferential sides more than the protruding portion 41 e of the firstlaminate steel plate 41 and the protruding portion 42 e of the secondlaminate steel plate 42. Also, a part of the protruding portion 43 e ofthe connected laminate steel plate 43 overlaps the penetrating portion41 b of the first laminate steel plate 41 and the penetrating portion 42b of the second laminate steel plate 42. As a result, the magnet 32inserted into the penetrating portion 41 b and the penetrating portion42 b is caught by the protruding portion 43 e. Therefore, it is possibleto prevent the magnet 32 from downwardly falling off the rotor core 40.

The connecting portions 43 k are disposed in regions between theconnected base portion 43 a and the connected annular portions 43 c inthe radial direction. The connecting portions 43 k are disposed atpredetermined intervals in the circumferential direction. The connectingportions 43 k are disposed in regions between the adjacent penetratingportions 43 b in the circumferential direction. The connecting portion43 k has an elongated plate or substantially elongated plate shapeextending in the radial direction in its shape in a plan view. Theconnecting portion 43 k connects the connected base portion 43 a and theconnected annular portion 43 c. More specifically, the connectingportion 43 k connects a radially front end portion of the protrudingportion 43 e and an inner edge portion of the small diameter portion 43g.

The small diameter portion 43 g has two coupling portions 43 m. Thecoupling portions 43 m are provided adjacent to both circumferentialsides of the connecting portion 43 k. That is, the small diameterportion 43 g has two coupling portions 43 m circumferentially adjacentto one connecting portion 43 k connected to the inner edge portionthereof. The coupling portion 43 m is connected to the large diameterportion 43 f on a side opposite to a region connected to the connectingportion 43 k.

In the rotor core 40 shown in FIG. 6 and FIG. 7, for example, oneconnected laminate steel plate 43 is disposed at the lower end in theaxial direction. At this time, the piece portion 41 c of the firstlaminate steel plate 41, the large diameter portion 42 f of the annularportion 42 c of the second laminate steel plate 42, and the largediameter portion 43 f of the connected annular portion 43 c of theconnected laminate steel plate 43 overlap in the axial direction, andthe first laminate steel plate 41, the second laminate steel plate 42and the connected laminate steel plate 43 are laminated at a positionwhere their outer edge portions are partially aligned.

According to this configuration, it is possible to further improve thestrength of the rotor core 40. Furthermore, it is possible to preventthe first base portion 41 a and the piece portion 41 c from beingseparated from each other, and the second base portion 42 a and theannular portion 42 c from being separated.

The connected laminate steel plate 43 may be disposed at the upper endin the axial direction of the rotor core 40. Further, the connectedlaminate steel plates 43 may be disposed at both the lower end and theupper end in the axial direction of the rotor core 40. According to thisconfiguration, it is possible to further increase the strength of therotor core 40. In addition, the connected laminate steel plate 43 at theupper end and the connected laminate steel plate 43 at the lower end mayhave different shapes. For example, the upper end may be a connectedlaminate steel plate 43 having penetrating portions through which themagnets 32 are inserted, and the lower end may be a connected laminatesteel plate 43 for preventing the magnets 32 from falling off.

Next, a motor according to a third preferred embodiment of the presentinvention will be described. FIG. 9 is a partial enlarged plan view of aconnected laminate steel plate of a rotor core according to a thirdpreferred embodiment of the present invention. Also, since a basicconfiguration of this embodiment is the same as that of the first andsecond preferred embodiments described above, constituent elementscommon to those preferred embodiments are denoted by the same referencenumerals or the same names as before and the explanation thereof may beomitted.

The rotor core 40 of the third preferred embodiment has a configurationin which, in the small diameter portion 43 g of the connected laminatesteel plate 43 shown in FIG. 9, two coupling portions 43 mcircumferentially adjacent to one connecting portion 43 k are cut fromthe large diameter portion 43 f. The coupling portions 43 m are cutinward from a radially outer side of the connected laminate steel plate43 with respect to the connected laminate steel plates 43 which arelaminated. Therefore, the rotor core 40 of the third preferredembodiment has a structure in which laminate steel plates obtained bycutting the coupling portions 43 m of the connected laminate steel plate43 are laminated in the axial direction.

The coupling portion 43 m is cut at a position close to the largediameter portion 43 f. The coupling portion 43 m is bent inward in theradial direction. The bent coupling portion 43 m is adjacent to thepenetrating portion 43 b side of the connecting portion 43 k.

Next, a manufacturing method of the rotor core 40, which is a motorcore, will be described with reference to FIGS. 10 and 11. FIG. 10 is aperspective view showing an preferred example of a cutting device usedin the manufacturing method of the rotor core according to the thirdpreferred embodiment of the present invention. FIG. 11 is a partialenlarged plan view showing an preferred example of a cutting tool usedin the manufacturing method of the rotor core according to the thirdpreferred embodiment of the present invention.

The manufacturing method of the rotor core 40 of the third preferredembodiment includes a process of laminating the connected laminate steelplates 43 in the axial direction. In this process, the connectedlaminate steel plates 43 are laminated from the upper end to the lowerend in the axial direction. In this way, the rotor core 40 of the thirdpreferred embodiment is formed only by the laminate steel plates inwhich the coupling portions 43 m of the connected laminate steel plate43 is cut. Also, in the process including the connected laminate steelplates 43, the first laminate steel plates 41, the second laminate steelplates 42, and the like may be laminated in combination.

Next, the manufacturing method of the rotor core 40 of the thirdpreferred embodiment includes a process of cutting the coupling portions43 m. In this process, for example, a cutting device 100 shown in FIG.10 is used.

The cutting device 100 includes a pedestal portion 101, a pressingmember 102, and a cutting tool 103. The rotor core 40 is placed on anupper surface of the pedestal portion 101 with the axial direction beingsubstantially vertical. A pressing member 102 is disposed above therotor core 40. The pressing member 102 holds the rotor core 40 betweenitself and the upper surface of the pedestal portion 101.

The cutting tool 103 is disposed on a radially outer side of the rotorcore 40 disposed on the upper surface of the pedestal portion 101. Thecutting tool 103 can move in the radial direction of the rotor core 40.The cutting tool 103 can press and abut its tip portion facing the outercircumferential surface of the rotor core 40 against the outercircumferential surface of the rotor core 40.

The cutting tool 103 has blade portions 103 a shown in FIG. 11 at a tipportion opposed to the outer circumferential surface of the rotor core40. The blade portions 103 a extend in the axial direction of the rotorcore 40.

The blade portions 103 a are provided at two locations separated in thecircumferential direction. Each of the two blade portions 103 a has acorner portion 103 b and a flat portion 103 c on an outer surface on itscircumferentially outer side. The two blade portions 103 a cut the twocoupling portions 43 m from the large diameter portion 43 f by using thecorner portion 103 b and the flat portion 103 c, respectively.

Since the manufacturing method of the rotor core 40 of the thirdpreferred embodiment includes the process of cutting the couplingportions 43 m of the connected laminate steel plate 43, it is possibleto eliminate the state in which the large diameter portions 43 f of theconnected annular portions 43 c adjacent to each other in thecircumferential direction are connected in the circumferential directionvia the small diameter portions 43 g. Thus, the leakage of the magneticflux that may occur at the coupling portion 43 m before cutting can besuppressed. Therefore, it is possible to suppress occurrence of amagnetic loop in the rotor core 40.

In the process of cutting the coupling portion 43 m, the connectedlaminate steel plate 43 is cut from the outer side to the inner side inthe radial direction. According to this configuration, the couplingportion 43 m of the connected annular portion 43 c can be cut using thecutting device 100 without requiring a high-power pressing device.Therefore, it is possible to suppress the increase in size and cost of amanufacturing device of the rotor core 40.

In the conventional manufacturing method of punching a laminate steelplate in the axial direction, an additional process such as ahalf-punching process or the like is necessary in advance. On the otherhand, the manufacturing method according to the modification of therotor core 40 of the second preferred embodiment can be formed into adesired shape without requiring an additional process.

Further, in the conventional manufacturing method of punching a laminatesteel plate in the axial direction, there is a possibility that sags orburrs may occur in the laminate steel plated at a lower end in the axialdirection of the rotor core. On the other hand, in the manufacturingmethod according to the modification of the rotor core 40 of the secondpreferred embodiment, the cutting is performed from the radially outerside. Thus, the cutting distance required for the cutting becomes shortin the laminate steel plate at a lower end of the rotor core 40 in theaxial direction, so that occurrence of sags and burrs can be prevented.

Next, the manufacturing method of the rotor core 40 of the thirdpreferred embodiment may include a process of removing the connectingportion 43 k. With this, occurrence of magnetic saturation that mayoccur at the connecting portion 43 k before removal can be suppressed.Therefore, it is possible to effectively suppress occurrence of amagnetic loop in the rotor core 40.

The configuration of the cutting device 100 described with reference toFIGS. 10 and 11 is an preferred example, and other configurations may beadopted as long as the connected laminate steel plate 43 can be cut fromthe outer side to the inner side in the radial direction.

Next, a first preferred example of the cutting process in themanufacturing method of the rotor core 40 will be described withreference to FIG. 12. FIG. 12 is a partial enlarged plan view of theconnected laminate steel plate showing the first preferred example ofthe cutting process in the manufacturing method of the rotor coreaccording to the third preferred embodiment of the present invention.

In the manufacturing method of the rotor core 40 of the third preferredembodiment, the first preferred example of the process of cutting thecoupling portion 43 m uses the cutting tool 103 shown in FIG. 11. Inthis cutting process shown in FIG. 12, coupling portions 43 m at twolocations circumferentially adjacent to one connecting portion 43 k aresimultaneously cut. As shown in FIG. 9, the coupling portions 43 m cutat the two locations are bent inward in the radial direction.

First, two coupling portions 43 m are simultaneously cut and bent. Next,the rotor core 40 is rotated around the central axis by the anglebetween the connecting portions 43 k adjacent to each other in thecircumferential direction. Subsequently, two coupling portions 43 mcircumferentially adjacent to the next one connecting portion 43 k aresimultaneously cut and bent. Subsequently, the cutting and bending oftwo coupling portions 43 m and the rotation of the rotor core 40 arerepeated over the entire outer edge portion of the rotor core 40.

According to this method, since the two coupling portions 43 m aresimultaneously cut, it is possible to minimize deformation of the rotorcore 40, in particular, deformation of the connecting portion 43 k whichmay occur at the time of cutting. Further, at the time of cutting, it ispossible to cut while holding one connecting portion 43 k disposedbetween two adjacent coupling portions 43 m. Thus, the efficiency of thecutting operation can be improved.

Next, a second preferred example of the cutting process in themanufacturing method of the rotor core 40 will be described withreference to FIG. 13. FIG. 13 is a plan view of the connected laminatesteel plate showing the second preferred example of the cutting processof the manufacturing method of the rotor core 40 according to the thirdpreferred embodiment of the present invention.

In the manufacturing method of the rotor core 40 of the third preferredembodiment, a cutting tool 104 having only one blade portion 103 a isused (see FIG. 13). In this cutting process shown in FIG. 13, couplingportions 43 m of a connected annular portion 43 c located at twolocations on circumferentially inner sides with respect to twoconnecting portions 43 k adjacent to each other in the circumferentialdirection are simultaneously cut. The cut coupling portions 43 m at thetwo locations are bent, for example, radially inward.

First, two coupling portions 43 m are simultaneously cut and bent. Next,the rotor core 40 is rotated around the central axis by the anglebetween connecting portions 43 k adjacent to each other in thecircumferential direction. Subsequently, two coupling portions 43 mlocated on the circumferentially inner sides with respect to the nexttwo connecting portions 43 k adjacent to each other in thecircumferential direction are cut and bent at the same time.Subsequently, the cutting and bending of two coupling portions 43 m andthe rotation of the rotor core 40 are repeated over the entire outeredge portion of the rotor core 40.

According to this method, since the two coupling portions 43 m aresimultaneously cut, it is possible to minimize deformation of the rotorcore 40, in particular, deformation of the connecting portion 43 k whichmay occur at the time of cutting. In addition, it is possible toequalize the shape and size of the large diameter portion 43 f of theconnected annular portion 43 c, which is a region between the twoconnecting portions 43 k adjacent to each other in the circumferentialdirection.

Next, a third preferred example of the cutting process in themanufacturing method of the rotor core 40 will be described withreference to FIG. 14. FIG. 14 is a plan view of a connected laminatesteel plate showing a third preferred example of the cutting process inthe manufacturing method of the rotor core according to the thirdpreferred embodiment of the present invention.

In the manufacturing method of the rotor core 40 of the third preferredembodiment, a cutting tool 104 having only one blade portion 103 a isused (see FIG. 14). In this cutting process shown in FIG. 14, couplingportions 43 m disposed at two locations on sides opposite to each otherwith the central axis located therebetween are simultaneously cut. Thecoupling portions 43 m at the two locations are bent, for example,radially inward.

First, two coupling portions 43 m are simultaneously cut and bent. Next,the rotor core 40 is rotated around the central axis by the anglebetween the connecting portions 43 k adjacent to each other in thecircumferential direction. Subsequently, the next two coupling portions43 m disposed on sides opposite to each other with the central axislocated therebetween are simultaneously cut and bent. Subsequently, thecutting and bending of two coupling portions 43 m and the rotation ofthe rotor core 40 are repeated over the entire outer edge portion of therotor core 40.

According to this method, since two coupling portions 43 m aresimultaneously cut, it is possible to minimize deformation of the rotorcore 40, in particular, deformation of the connecting portion 43 k whichmay occur at the time of cutting.

The cutting process used in the third preferred embodiment is notlimited to the rotor core as long as it is a motor core, and it may beadopted for a stator core. For example, a process of cutting toward aslot provided in a stator core may be considered.

Next, a motor according to a fourth preferred embodiment of the presentinvention will be described. FIG. 15 is a perspective view of a rotorcore of the motor according to the fourth preferred embodiment of thepresent invention as viewed from above. FIG. 16 is a perspective view ofthe rotor core of the motor according to the fourth preferred embodimentof the present invention as viewed from below. FIG. 17 is a plan view ofa connected laminate steel plate of the rotor core according to thefourth preferred embodiment of the present invention. Since a basicconfiguration of this preferred embodiment is the same as that of thefirst and second preferred embodiments described above, constituentelements common to those preferred embodiments are denoted by the samereference numerals or same names as before, and explanation thereof maybe omitted.

The rotor core 40 shown in FIGS. 15 and 16 has a connected laminatesteel plate 44 in addition to the first laminate steel plates 41 and thesecond laminate steel plates 42. Similarly to the first laminate steelplate 41 and the second laminate steel plate 42, the connected laminatesteel plate 44 expands in the radial direction with respect to thecentral axis of the rotor core 40.

The connected laminate steel plate 44 shown in FIG. 17 has a connectedbase portion 44 a, penetrating portions 44 b, connected piece portions44 c, and connecting portion 44 k.

The connected base portion 44 a has recessed portions 44 e. The recessedportions 44 e are provided in angular regions with respect to thecentral axis between the connected piece portions 44 c adjacent to eachother in the circumferential direction. That is, the recessed portions44 e are provided in fan-shaped regions surrounded by circumferentiallyopposed end portions of circumferentially adjacent connected pieceportions 44 c and the central axis, respectively. In other words, therecessed portions 44 e are provided in the column portions 33 a of therotor 3. An preferred example of the fan-shaped angular region withrespect to the center axis between the circumferentially adjacentconnected piece portions 44 c is illustrated with a one-dot chain linein FIG. 17.

The recessed portion 44 e is recessed radially inward from an outer edgeportion 44 w of the connected base portion 44 a. When the connected baseportion 44 a is polygonal, the recessed portion 44 e is recessedradially inward from each apex of the connected base portion 44 a. Sincethe connected base portion 44 a has the recessed portions 44 e, when asynthetic resin, adhesive or the like is poured on radially outer sidesof the first base portion 41 a, the second base portion 42 a and theconnected base portion 44 a after inserting the magnets 32 into thepenetrating portions 41 b and 42 b, the synthetic resin, adhesive, etc.enter the recessed portions 44 e. Thus, it is possible to firmly fix theconnected piece portions 44 c and the magnets 32.

The penetrating portion 44 b is formed as a gap between the connectedbase portion 44 a and the connected piece portion 44 c. Connectingportions 44 k are provided on both circumferential sides of thepenetrating portion 44 b. The connecting portion 44 k overlaps thepenetrating portion 41 b of the first laminate steel plate 41 and thepenetrating portion 42 b of the second laminate steel plate 42. As aresult, the magnet 32 inserted into the penetrating portion 41 b and thepenetrating portion 42 b is caught by the connecting portion 44 k.Therefore, it is possible to prevent the magnet 32 from downwardlyfalling off the rotor core 40.

The connected piece portion 44 c is separately disposed on a radiallyouter side of the connected base portion 44 a with the penetratingportion 44 b therebetween. The separation mentioned here includes a formin which the connected piece portion 44 c and the connected base portion44 a are partially connected by the connecting portion 44 k. Forexample, eight connected piece portions 44 c are disposed atpredetermined intervals in the circumferential direction. The center ofthe connected piece portion 44 c is shifted radially outward from theaxis of the shaft 31 in its shape in a plan view, and the connectedpiece portion 44 c is in a semicircular or substantially semicircularshape which has an arc having a radius smaller than the radius of therotor 3 and a straight portion corresponding to a string positioned onthe radially inner side of the arc. The straight portion on the radiallyinner side of the connecting piece portion 44 c is substantiallyparallel to the outer edge portion 44 w of the connected base portion 44a.

The connecting portions 44 k are disposed in regions between theconnected base portion 44 a and the connected piece portions 44 c in theradial direction. The connecting portions 44 k are provided oncircumferential end portions of the connected piece portion 44 c withrespect to one connected piece portion 44 c, respectively, and extend inparallel to each other. The connecting portions 44 k have an elongatedplate or substantially elongated plate shape extending in asubstantially radial direction in their shape in a plan view. Theconnecting portions 44 k connect the connected base portion 44 a and theconnected piece portions 44 c. More specifically, the connectingportions 44 k connect both circumferential side regions of the recessedportion 44 e and straight portions of the connecting piece portions 44 cat both circumferential ends.

In the rotor core 40 shown in FIGS. 15 and 16, for example, two secondlaminate steel plates 42 are disposed at the upper end and a lowerportion in the axial direction, and a plurality of first laminate steelplates 41 are disposed between the second laminate steel plate 42 at theupper end in the axial direction and the second laminate steel plate 42at the lower portion in the axial direction. For example, two secondlaminate steel plates 42 are disposed also in a middle portion of theplurality of first laminate steel plates 41 laminated in the axialdirection. Further, for example, one connected laminate steel plate 44is disposed at the lower end in the axial direction. At this time, thepiece portion 41 c of the first laminate steel plate 41, the largediameter portion 42 f of the annular portion 42 c of the second laminatesteel plate 42, and the connected piece portion 44 c of the connectedlaminate steel plate 44 overlap in the axial direction, and the firstlaminate steel plate 41, the second laminate steel plate 42 and theconnected laminate steel plate 44 are laminated at a position wheretheir outer peripheral edges are partially aligned.

According to this configuration, it is possible to further improve thestrength of the rotor core 40. In addition, when the magnet 32 isinserted into the penetrating portions 41 b and 42 b, the magnet 32 iscaught by the connecting portions 44 k in the axial direction. Thismakes it possible to prevent the magnet 32 from falling off the rotorcore 40. Furthermore, it is possible to prevent the first base portion41 a and the piece portions 41 c from being separated from each other,and the second base portion 42 a and the annular portions 42 c frombeing separated.

The connected laminate steel plate 44 may be disposed at the upper endin the axial direction of the rotor core 40. Also, the connectedlaminate steel plates 44 may be disposed at both the lower end and theupper end in the axial direction of the rotor core 40. According to thisconfiguration, it is possible to further increase the strength of therotor core 40. Further, the upper connected laminate steel plate 44 andthe lower connected laminate steel plate 44 may have different shapes.For example, the upper end may be a connected laminate steel plate 44having penetrating portions through which the magnets 32 are inserted,and the lower end may be a connected laminate steel plate 44 forpreventing the magnets 32 from falling off.

In the rotor core 40, the first laminate steel plate 41 has theprotruding portion 41 e, the second laminate steel plate 42 has theprotruding portion 42 e, and the connected laminate steel plate 44 hasthe recessed portion 44 e. The magnet 32 can be brought into contactwith the protruding portions 41 e and 42 e when the magnet 32 isinserted into the penetrating portions 41 b and 42 b. Accordingly, thepositioning of the magnet 32 can be performed in the circumferentialdirection. Further, when a synthetic resin, an adhesive or the like ispoured on a radially outer side of the first base portion 41 a or thelike after inserting the magnet 32 into the penetrating portions 41 band 42 b, the synthetic resin, adhesive or the like intrudes into therecessed portions 44 e. Thus, the magnet 32 can be firmly fixed.Therefore, it is possible to realize both positioning of the magnet 32and firm fixation of the magnet 32.

Next, a motor according to a fifth preferred embodiment of the presentinvention will be described. FIG. 18 is a perspective view of a rotorcore of the motor according to the fifth preferred embodiment of thepresent invention as viewed from above. FIG. 19 is a perspective view ofthe rotor core of the motor according to the fifth preferred embodimentof the present invention as viewed from below. FIG. 20 is a plan view ofa connected laminate steel plate of the rotor core according to thefifth preferred embodiment of the present invention. Since a basicconfiguration of this preferred embodiment is the same as the first,second and third preferred embodiments described above, constituentelements common to those preferred embodiments are denoted by the samereference numerals or same names as before, and explanation thereof maybe omitted.

The rotor core 40 shown in FIGS. 18 and 19 has a connected laminatesteel plate 45 in addition to the first laminate steel plate 41 and thesecond laminate steel plate 42. Similarly to the first laminate steelplate 41 and the second laminate steel plate 42, the connected laminatesteel plate 45 expands in the radial direction with respect to thecentral axis of the rotor core 40.

The connected laminate steel plate 45 shown in FIG. 20 has a connectedbase portion 45 a, penetrating portions 45 b, connected piece portions45 c, and connecting portions 45 k.

The connected base portion 45 a, the penetrating portion 45 b, and theconnected piece portion 45 c have the same configuration as theconnected base portion 44 a, the penetrating portion 44 b and theconnecting piece portion 44 c of the connected laminate steel plate 44of the fourth preferred embodiment. That is, the connected base portion45 a has a hole portion 45 d and recessed portions 45 e.

The penetrating portion 45 b is configured as a gap between theconnected base portion 45 a and the connected piece portion 45 c. Theconnecting portions 45 k are provided on both circumferential sides ofthe penetrating portion 45 b. The connecting portions 45 k overlap thepenetrating portion 41 b of the first laminate steel plate 41 and thepenetrating portion 42 b of the second laminate steel plate 42. As aresult, the magnet 32 inserted into the penetrating portion 41 b and thepenetrating portion 42 b is caught by the connecting portions 45 k.Therefore, it is possible to prevent the magnet 32 from downwardlyfalling off the rotor core 40.

The connected piece portion 45 c is separately disposed on a radiallyouter side of the connected base portion 45 a with the penetratingportion 45 b therebetween. The separation mentioned here includes a formin which the connected piece portion 45 c and the connected base portion45 a are partially connected by the connecting portion 45 k. Forexample, eight connected piece portions 45 c are disposed atpredetermined intervals in the circumferential direction. The center ofthe connected piece portion 45 c is shifted radially outward from theaxis of the shaft 31 in its shape in a plan view, and the connectedpiece portion 45 c is in a semicircular or substantially semicircularshape which has an arc having a radius smaller than the radius of therotor 3 and a straight portion corresponding to a string positioned onthe radially inner side of the arc. The straight portion on the radiallyinner side of the connecting piece portion 45 c is substantiallyparallel to an outer edge portion 45 w of the connected base portion 45a.

The connecting portions 45 k are disposed in regions between theconnected base portion 45 a and the connected piece portions 45 c in theradial direction. The connecting portions 45 k are provided at twolocations inward from circumferential end portions of the connectedpiece portion 45 c with respect to one straight portion of the connectedpiece portion 45 c, and extend in parallel to each other. The connectingportions 45 k connect the outer edge portion 45 w of the connected baseportion 45 a and the straight portion of the connected piece portion 45c. The connecting portions 45 k have an elongated plate or substantiallyelongated plate shape extending in a radial or substantially radialdirection in their shape in a plan view.

In the rotor core 40 shown in FIGS. 18 and 19, for example, two secondlaminate steel plates 42 are disposed at the upper end and a lowerportion in the axial direction, and a plurality of first laminate steelplates 41 are disposed between the second laminate steel plate 42 at theupper end in the axial direction and the second laminate steel plate 42at the lower portion in the axial direction. For example, two secondlaminate steel plates 42 are disposed also in a middle portion of theplurality of first laminate steel plates 41 laminated in the axialdirection. Further, for example, one connected laminate steel plate 45is disposed at the lower end in the axial direction. At this time, thepiece portion 41 c of the first laminate steel plate 41, the largediameter portion 42 f of the annular portion 42 c of the second laminatesteel plate 42, and the connected piece portion 45 c of the connectedlaminate steel plate 45 overlap in the axial direction, and the firstlaminate steel plate 41, the second laminate steel plate 42 and theconnected laminate steel plate 45 are laminated at a position wheretheir outer edge portions are partially aligned.

According to this configuration, it is possible to further improve thestrength of the rotor core 40. Further, when the magnet 32 is insertedinto the penetrating portions 41 b and 42 b, the magnet 32 is caught bythe connecting portions 45 k in the axial direction. This makes itpossible to prevent the magnet 32 from falling off the rotor core 40.Furthermore, it is possible to prevent the first base portion 41 a andthe piece portion 41 c from being separated from each other, and thesecond base portion 42 a and the annular portion 42 c from beingseparated.

In addition, the connected laminate steel plate 45 may be disposed atthe upper end in the axial direction of the rotor core 40. Also, theconnected laminate steel plates 45 may be disposed at both the lower endand the upper end in the axial direction of the rotor core 40. Accordingto this configuration, it is possible to further increase the strengthof the rotor core 40. Further, the connected laminate steel plate 45 atthe upper end and the connected laminate steel plate 45 at the lower endmay have different shapes. For example, the upper end may be a connectedlaminate steel plate 45 having penetrating portions through which themagnets 32 are inserted, and the lower end may be a connected laminatesteel plate 45 for preventing the magnets 32 from falling off.

Also, in the rotor core 40, the first laminate steel plate 41 has theprotruding portion 41 e, the second laminate steel plate 42 has theprotruding portion 42 e, and the connected laminate steel plate 45 hasthe recessed portion 45 e. The magnet 32 can be brought into contactwith the protruding portions 41 e and 42 e when the magnet 32 isinserted into the penetrating portions 41 b and 42 b. Accordingly, thepositioning of the magnet 32 can be performed in the circumferentialdirection. Further, when a synthetic resin, an adhesive or the like ispoured on a radially outer side of the first base portion 41 a or thelike after inserting the magnet 32 into the penetrating portions 41 band 42 b, the synthetic resin, adhesive or the like intrudes into therecessed portions 45 e. Thus, the magnet 32 can be firmly fixed.Therefore, it is possible to realize both positioning of the magnet 32and firm fixation of the magnet 32.

Subsequently, a first modification of the rotor core 40 of the fifthpreferred embodiment will be described. FIG. 21 is a perspective view ofthe first modification of the rotor core according to the fifthpreferred embodiment of the present invention as seen from above. FIG.22 is a perspective view of the first modification of the rotor coreaccording to the fifth preferred embodiment of the present invention asviewed from the below.

In the first modification of the rotor core 40 of the fifth preferredembodiment, the rotor core 40 shown in FIGS. 21 and 22 has a connectedlaminate steel plate 45 in addition to the first laminate steel plate 41and the second laminate steel plate 42. The connected laminate steelplate 45 is disposed at the lower end in the axial direction of therotor core 40.

As shown in FIG. 22, the connected laminate steel plate 45 hasconnecting portions 45 k as an intervening portion interposed betweenthe connected base portion 45 a and the connected piece portion 45 c.Also, the intervening portion mentioned here includes, in addition tothe connecting portion 45 k, an outward projection provided in theconnected base portion 45 a, an inward projection provided in theconnected piece portion 45 c, and a configuration in which a spacebetween the connected base portion 45 a and the connected piece portion45 c is filled with a steel plate member.

According to this configuration, the magnet 32 inserted into thepenetrating portion 41 b and the penetrating portion 42 b is caught bythe intervening portion at the lower portion of the rotor core 40.Therefore, it is possible to prevent the magnet 32 from downwardlyfalling off the rotor core 40. Further, since the connected base portion45 a and the connected piece portion 45 c are connected via theconnecting portions 45 k, it is possible to prevent the first baseportion 41 a and the piece portion 41 c from being separated from eachother and the second base portion 42 a and the annular portion 42 c frombeing separated.

As shown in FIG. 21, the second laminate steel plate 42 disposed at theaxially upper end of the rotor core 40 has outward projections 42 n. Theoutward projections 42 n extend radially outward from the outer edgeportion 42 w of the second base portion 42 a. A projecting length of theoutward projection 42 n is shorter than the radial width of thepenetrating portion 42 b. The magnet 32 is inserted into the penetratingportion 41 b and the penetrating portion 42 b below the second laminatesteel plate 42 disposed at the axially upper end of the rotor core 40.

According to this configuration, the magnet 32 is caught by the outwardprojections 42 n at the upper portion of the rotor core 40. Therefore,it is possible to prevent the magnet 32 from upwardly coming out of therotor core 40.

Subsequently, a second modification of the rotor core 40 of the fifthpreferred embodiment will be described. FIG. 23 is a longitudinal endview showing a first step of the manufacturing method of the secondmodification of the rotor core according to the fifth preferredembodiment of the present invention. FIG. 24 is a longitudinal end viewshowing a second step of the manufacturing method of the secondmodification of the rotor core according to the fifth preferredembodiment of the present invention. FIG. 25 is a longitudinal end viewshowing a third step of the manufacturing method of the secondmodification of the rotor core according to the fifth preferredembodiment of the present invention.

In the second modification of the rotor core 40 of the fifth preferredembodiment, the connected laminate steel plate 45 is disposed at theupper end in the axial direction of the rotor core 40. Alternatively, inthe second modification of the rotor core 40 of the fifth preferredembodiment, the connected laminate steel plate 45 is disposed at boththe upper end and the lower end in the axial direction of the rotor core40.

As shown in FIG. 25, the connecting portions 45 k of the connectedlaminate steel plate 45 at the axially upper end is cut inward from theaxially upper side of the connected laminate steel plate 45 with respectto the connected laminate steel plate 45 that is laminated. The cutconnecting portions 45 k are bent toward the inside of the penetratingportion 45 b. In this way, by cutting the connecting portions 45 k, theoutward projections 45 n can be formed. Also, inward projections may beformed by a similar cutting process.

The manufacturing method of the second modification of the rotor core 40of the fifth preferred embodiment includes a process of laminatingdivided laminate steel plates in the axial direction. The dividedlaminate steel plate corresponds to the first laminate steel plate 41 inwhich the first base portion 41 a and the piece portion 41 c are dividedin the radial direction. In this process, a plurality of first laminatesteel plates 41 are laminated in the axial direction. In addition, therotor core 40 also includes a plurality of second laminate steel plates42 having a smaller number of laminated layers than the first laminatesteel plates 41.

Next, the manufacturing method according to the second modification ofthe rotor core 40 of the fifth preferred embodiment includes a processof further laminating the connected laminate steel plate 45 to the firstlaminate steel plates 41 that ate laminated. In this process, theconnected laminate steel plate 45, in which the connected base portion45 a and the connected piece portion 45 c are connected via theconnecting portions 45 k, is laminated on the axially upper end of thefirst laminate steel plates 41 that are laminated. Further, in themanufacturing method of the second modification of the rotor core 40 ofthe fifth preferred embodiment, the connected laminate steel plate 45 (aintervened laminate steel plate) in which the connecting portions 45 kas an intervening portion are interposed between the connected baseportion 45 a and the connected piece portion 45 c is laminated on theaxially lower end of the first laminate steel plates 41 that arelaminated. In these lamination processes, the piece portion 41 c of thefirst laminate steel plate 41 and the connected piece portion 45 c ofthe connected laminate steel plate 45 overlap in the axial direction,and the first laminate steel plate 41 and the connected laminate steelplate 45 are laminated at a position where their outer edge portions arepartially aligned.

Next, the manufacturing method of the second modification of the rotorcore 40 of the fifth preferred embodiment includes a process of cuttingthe connecting portions 45 k with a cutting member 200. In this process,the cutting member 200 is inserted into the penetrating portion 45 b(not shown) of the connected laminate steel plate 45 shown in FIGS. 23,24, and 25 to cut the connecting portions 45 k with the cutting member200. In this way, it is possible to eliminate the state in which theconnected base portion 45 a and the connected piece portion 45 c areconnected. Therefore, a flux barrier such as an air layer can beprovided between the connected base portion 45 a and the connected pieceportion 45 c. Thus, it is possible to reduce the magnetic flux loop.

The cutting member 200 shown in FIG. 23 is made of metal, for example,and is a rectangular parallelepiped body which has a rectangular orsubstantially rectangular shape in a cross-section intersecting theaxial direction and extends in the axial direction, similarly to themagnet 32. The magnet 32 may be used for the cutting member. In thisway, it is possible to reduce the number of members to be used, and itis possible to reduce the number of processes until the rotor 3 isformed. Further, since the magnet 32 and the resin are in contact witheach other, the fastening strength can be improved. In the first step ofthe cutting process for the connecting portion 45 k shown in FIG. 23,the cutting member 200 is disposed axially above the position where aradially outer edge portion of the cutting member 200 coincides with aconnection portion between the connecting portion 45 k and the connectedpiece portion 45 c in the radial direction of the rotor core 40.

Here, the rotor core 40 has a penetrating portion 50. The penetratingportion 50 is configured by the penetrating portion 41 b of the firstlaminate steel plate 41 and the penetrating portion 42 b of the secondlaminate steel plate 42 which mutually overlap in the axial direction,and extends in the axial direction.

The penetrating portion 50 has a first penetrating portion 51 and asecond penetrating portion 52. The second penetrating portion 52 has anarrower radial width than the first penetrating portion 51. The secondpenetrating portion 52 has a radial width that can accommodate only themagnet 32. The first penetrating portion 51 has a wider radial widththan the second penetrating portion 52. The first penetrating portion 51has a radial width that can accommodate an outward projection 45 n,which will be described later, in addition to the magnet 32.

The first penetrating portion 51 is formed at an upper portion of therotor core 40 by a predetermined number of the penetrating portions 41 bof first laminate steel plates 41 and the penetrating portions 42 b ofthe second laminate steel plates 42 which are laminated adjacent to alower surface of the connected laminate steel plate 45. The secondpenetrating portion 52 is formed by the penetrating portions 41 b of thefirst laminate steel plates 41 and the penetrating portions 42 b of thesecond laminate steel plates 42 at a position below the first laminatesteel plates 41 and the second laminate steel plates 42 which areprovided with the first penetrating portion 51.

In the second step of the cutting process of the connecting portion 45 kshown in FIG. 24, the cutting member 200 descends and the connectingportion 45 k is cut. The connecting portion 45 k is cut at a portionconnected to the connected piece portion 45 c. The cut connectingportion 45 k becomes the outward projection 45 n of the connected baseportion 45 a. The outward projection 45 n extends radially outward fromthe outer edge portion 45 w of the connected base portion 45 a. Theoutward projection 45 n is bent toward the first penetrating portion 51at a root portion of the connected base portion 45 a.

In the third step of the cutting process of the connecting portion 45 kshown in FIG. 25, the cutting member 200 further proceeds to be lowered,and a bent portion of the outward projection 45 n is accommodated insidethe first penetrating portion 51. After cutting the connecting portion45 k with the cutting member 200, the cutting member 200 is removed fromthe penetrating portion 50.

Next, the manufacturing method of the second modification of the rotorcore 40 of the fifth preferred embodiment includes a process ofinserting the magnet 32 into the penetrating portion 50. When the magnet32 is used as the cutting member, the magnet 32 is inserted into thepenetrating portion 50 after cutting the connecting portion 45 k.

Also, when the connected laminate steel plate 45 is disposed at theaxially lower end of the rotor core 40, the magnet 32 is brought intocontact with an upper surface of the connecting portion 45 k, which isthe intervened portion of the connected laminate steel plate 45, at theaxially lower end in a final step of insertion into the penetratingportion 50.

Next, the manufacturing method of the second modification of the rotorcore 40 of the fifth preferred embodiment includes a process of formingthe resin portion 34. In this process, the resin portion 34 is formed bypouring a synthetic resin, an adhesive agent or the like into the spaceportion 33.

In the rotor core 40 of the second modification of the fifth preferredembodiment, the connected laminate steel plate 45 disposed at theaxially upper end has the outward projection 45 n which extends radiallyoutward from the outer edge portion 45 w of the connected base portion45 a. According to this configuration, a flux barrier such as an airlayer or a resin layer 34 can be provided between the connected baseportion 45 a and the connected piece portion 45 c of the connectedlaminate steel plate 45. This makes it possible to more effectivelyutilize the magnetic flux of the magnet 32. Further, before forming theoutward projection 45 n, that is, before cutting the connecting portion45 k, it is possible to prevent the first base portion 41 a and thepiece portion 41 c from being separated from each other and the secondbase portion 42 a and the annular portion 42 c from being separated.

In addition, instead of the outward projection 45 n, the rotor core 40may be provided with an inward projection extending radially inward fromthe inner edge portion of the connected piece portion 45 c. Further, therotor core 40 may be provided with both of the outward projection 45 nand the inward projection.

Since the outward projection 45 n is bent toward the penetrating portion50, it presses the magnet 32 outward in the radial direction with itselastic force. Thus, the positioning of the magnet 32 can be performedin the radial direction. Further, it is possible to enhance the functionof fixing the magnet 32 to the rotor core 40. In addition, the inwardprojection in the first modification and the outward projection 45 n inthe second modification may be combined. In this case, since the outwardprojection 45 n is pressed radially outward, it can be caught by theinward projection and thus prevented from falling off.

Since a bent portion of the outward projection 45 n is accommodatedinside the first penetrating portion 51, it does not interfere with theinsertion of the magnet 32 into the penetrating portion 50. Therefore,it is possible to secure a space for inserting the magnet 32 in thepenetrating portion 50.

Also, the manufacturing method according to the second modification ofthe rotor core 40 of the fifth preferred embodiment may include aprocess of forming the thickness of the connecting portion 45 k in theaxial direction to be thinner than those of the connected base portion45 a and the connected piece portion 45 c before the process of cuttingthe connecting portion 45 k with the cutting member 200. According tothis configuration, it is possible to easily cut the connecting portion45 k. For example, press working may be performed. According to thisconfiguration, it is possible to obtain a configuration capable ofeasily cutting the connecting portion 45 k by a simple processingmethod.

Also, the manufacturing method according to the second modification ofthe rotor core 40 of the fifth preferred embodiment may include aprocess of providing a notch N, an example of which being shown in FIG.32, in the connecting portion 45 k before the process of cutting theconnecting portion 45 k with the cutting member 200. According to thisconfiguration, it is possible to easily cut the connecting portion 45 k.For example, push back processing may be performed. According to thisconfiguration, it is possible to obtain a configuration capable ofeasily cutting the connecting portion 45 k by a simple processingmethod.

Next, a motor according to a sixth preferred embodiment of the presentinvention will be described. FIG. 26 is a perspective view of a rotorcore of the motor according to the sixth preferred embodiment of thepresent invention as viewed from above. FIG. 27 is a perspective view ofthe rotor core of the motor according to the sixth preferred embodimentof the present invention as viewed from below. FIG. 28 is a plan view ofa first laminate steel plate of the rotor core according to the sixthpreferred embodiment of the present invention. FIG. 29 is a plan view ofa second laminate steel plate of the rotor core according to the sixthpreferred embodiment of the present invention. Since a basicconfiguration of this preferred embodiment is the same as that of thefirst preferred embodiment described above, constituent elements commonto those in the first preferred embodiment are denoted by the samereference numerals or the same names as before, and explanation thereofmay be omitted.

The rotor core 40 shown in FIGS. 26 and 27 has first laminate steelplates 46 and second laminate steel plates 47. Each of the firstlaminate steel plates 46 and the second laminate steel plates 47 expandsin the radial direction with respect to the central axis of the rotorcore 40.

The first laminate steel plate 46 shown in FIG. 28 has a first baseportion 46 a, penetrating portions 46 b, and piece portions 46 c. Thefirst base portion 46 a has a hole portion 46 d and recessed portions 46e.

The second laminate steel plate 47 shown in FIG. 29 has a second baseportion 47 a, penetrating portions 47 b, and annular portions 47 c. Thesecond base portion 47 a has a hole portion 47 d and recessed portions47 e. The annular portion 47 c has a large diameter portion 47 f andsmall diameter portions 47 g which have different outer diameters.

The rotor core 40 shown in FIG. 26 and FIG. 27 is formed by laminating aplurality of first laminate steel plates 46 having the above-describedstructure and at least one second laminate steel plate 47 having theabove structure in the axial direction. At this time, the piece portion46 c of the first laminate steel plate 46 and the large diameter portion47 f of the annular portion 47 c of the second laminate steel plate 47overlap in the axial direction, and the first laminate steel plate 46and the second laminate steel plate 47 are laminated at a position wheretheir outer peripheral edges are partially aligned.

According to this configuration, there is no region of a steel plateover the entire region in the circumferential direction between thefirst base portion 46 a and the piece portions 46 c of the firstlaminate steel plate 46 and between the second base portion 47 a and theannular portions 47 c of the second laminate steel plate 47. As aresult, a flux barrier such as an air layer can be provided between thefirst base portion 46 a and the piece portion 46 c and between thesecond base portion 47 a and the annular portion 47 c. Therefore, it ispossible to more effectively utilize the magnetic flux of the magnet 32.

Since the number of the second laminate steel plates 47 is smaller thanthe number of the first laminate steel plates 46, it is possible tosuppress the amount of magnetic flux flowing through the annularportions 47 c of the entire rotor core 40 as compared with the casewhere all of the rotor core 40 is formed by the second laminate steelplates 47. Therefore, the occurrence of magnetic saturation in theannular portion 47 c is suppressed, so that the magnetic flux of themagnet 32 can be more effectively utilized.

When a synthetic resin, an adhesive or the like is poured on radiallyouter sides of the first base portion 46 a and the second base portion47 a after inserting the magnet 32 into the penetrating portions 46 band 47 b, the synthetic resin, adhesive or the like intrudes into therecessed portions 46 e and 47 e. Thus, it is possible to firmly fix thepiece portion 46 c, the annular portion 47 c, and the magnet 32.

Next, a motor according to an exemplary seventh preferred embodiment ofthe present invention will be described. FIG. 30 is a perspective viewof a rotor of the motor according to the seventh preferred embodiment ofthe present invention as seen from above. FIG. 31 is a plan view of therotor of the motor according to the seventh preferred embodiment of thepresent invention. Also, since a basic configuration of this preferredembodiment is the same as that of the first preferred embodimentdescribed above, constituent elements common to the first preferredembodiment are denoted by the same reference numerals or same names asbefore, and explanation thereof may be omitted.

The rotor 3 shown in FIGS. 30 and 31 has a cylindrical or substantiallycylindrical shape extending in the axial direction. The rotor 3 isdisposed with a predetermined gap provided radially inside a stator 2(see FIG. 1). The rotor 3 has a shaft 31 (not shown), a rotor core 40,magnets 32, and space portions 33 or resin portions 34.

The resin portion 34 is provided by injecting a synthetic resin, anadhesive agent or the like into the space portion 33. As a result, theresin portion 34 plays a role as a flux barrier. Further, since bothcircumferential ends of the magnet 32 contact the resin portions 34, itis possible to firmly fix the magnet 32 to the rotor core 40.

The rotor core 40 has first laminate steel plates 46. The first laminatesteel plate 46 has a first base portion 46 a, penetrating portions 46 b,and piece portions 46 c. The first base portion 46 a has a hole portion46 d and recessed 46 e.

The penetrating portion 46 b is formed as a gap between the first baseportion 46 a and the piece portion 46 c. The magnets 32 are provided oneby one for each of eight penetrating portions 46 b. Eight columnportions 33 a are disposed between adjacent penetrating portions 46 b(magnets 32) in the circumferential direction and pass through the rotorcore 40 in the axial direction.

A circumferential length L1 of the piece portion 46 c shown in FIG. 31is shorter than a circumferential length L2 of the magnet 32. Accordingto this configuration, the magnetic characteristics related to a coggingtorque can be improved. Therefore, it is possible to reduce the coggingtorque. Furthermore, it is possible to suppress the generation of themagnetic flux loop inside the rotor core 40.

The recessed portion 46 e is provided in an angular region with respectto the central axis between the piece portions 46 c adjacent to eachother in the circumferential direction. The recessed portion 46 e isrecessed radially inward from an outer edge portion 46 w of the firstbase portion 46 a. According to this configuration, when a syntheticresin, an adhesive or the like is poured on a radially outer side of thefirst base portion 46 a after the magnet 32 is inserted between thefirst base portion 46 a and the piece portion 46 c, that is, thepenetrating portion 46 b, the synthetic resin, adhesive or the likeintrudes into the recessed portion 46 e. Thus, it is possible to firmlyfix the piece portion 46 c and the magnet 32.

Although the preferred embodiments of the present invention have beendescribed above, the scope of the present invention is not limitedthereto, and various modifications can be made without departing fromthe spirit of the invention. Further, the above preferred embodimentsand modifications thereof can be arbitrarily combined as appropriate.

For example, although the annular portions 42 c and 47 c and theconnected annular portion 43 c described in the above embodiments areannularly connected over the entire circumference, a part of them in thecircumferential direction may be in a locally discontinued shape.

Further, in the second, third and fourth embodiments, the connectedlaminate steel plate is arranged only at the lower end in the axialdirection, the connected laminate steel plates may be disposed at bothof the lower end and the upper end in the axial direction. In the casewhere the connected laminate steel plates are disposed at both of thelower end and the upper end in the axial direction, the connectedlaminate steel plates having different shapes may be disposed at thelower end and the upper end in the axial direction.

In addition, as the stator according to the embodiment of the presentinvention, a stator such as a claw pole type is also applicable.

The present invention can be used, for example, in rotor cores, rotors,and motors.

Features of the above-described preferred embodiments and themodifications thereof may be combined appropriately as long as noconflict arises.

While preferred embodiments of the present invention have been describedabove, it is to be understood that variations and modifications will beapparent to those skilled in the art without departing from the scopeand spirit of the present invention. The scope of the present invention,therefore, is to be determined solely by the following claims.

The invention claimed is:
 1. A rotor core comprising: a plurality oflaminate steel plates each extending in a radial direction with respectto a central axis; each of the laminate steel plates including: a baseportion positioned on a radially outer side of the central axis; and aplurality of pieces separately disposed on a radially outer side of thebase portion with penetrating portions therebetween, and arranged sideby side at predetermined intervals in a circumferential direction;wherein the plurality of laminate steel plates are laminated in an axialdirection; the laminated steel plate disposed at an upper end in theaxial direction includes at least one of an outward projection extendingradially outward from an outer edge portion of the base portion and aninward projection extending radially inward from an inner edge portionof the piece; the laminated steel plate disposed at a lower end in theaxial direction includes an intervening portion that intervenes betweenthe base portion and the piece; the outward projection or the inwardprojection bends toward the penetrating portion; the penetratingportions include a first penetrating portion and a second penetratinginside the first penetrating portion; and a bent portion of the outwardprojection or the inward projection is accommodated inside the firstpenetrating portion.
 2. The rotor core according to claim 1, wherein theintervening portion is a connecting portion which connects the baseportion and the piece.
 3. The rotor core according to claim 1, wherein,in an angular region with respect to the central axis between the piecesadjacent to each other in the circumferential direction, the baseportion includes protruding portions protruding radially outward from anouter edge portion thereof.
 4. The rotor core according to claim 1,wherein, in an angular region with respect to the central axis betweenthe pieces adjacent to each other in the circumferential direction, thebase portion includes recessed portions recessed radially inward from anouter edge portion thereof.
 5. A rotor comprising: the rotor coreaccording to claim 1; and a plurality of magnets disposed in thepenetrating portions of the rotor core; wherein the rotor core includesa plurality of space portions which are disposed between the penetratingportions adjacent to each other in the circumferential direction, andpenetrate the rotor core in the axial direction.
 6. The rotor accordingto claim 5, further comprising a resin portion provided in the spaceportion.
 7. A motor comprising the rotor according to claim
 5. 8. Amanufacturing method of a rotor core in which a plurality of laminatesteel plates extending in a radial direction with respect to a centralaxis are laminated in an axial direction, the method comprising:laminating divided laminate steel plates in the axial direction, each ofthe divided laminate steel plates including a base portion positioned ona radially outer side of the central axis, and a plurality of piecesseparately disposed on a radially outer side of the base portion withpenetrating portions therebetween, and arranged side by side atpredetermined intervals in a circumferential direction; laminating aconnected laminate steel plate including the base portion and the piecesconnected via connecting portions at an upper end in the axial directionof the divided laminate steel plates that are laminated; laminating anintervening laminate steel plate including intervening portions thatintervene between the base portion and the pieces at a lower end in theaxial direction of the divided laminate steel plates that are laminated;and cutting the connecting portions with a cutter by inserting thecutter into the penetrating portions; wherein a laminated steel platedisposed at an upper end in the axial direction includes at least one ofan outward projection extending radially outward from an outer edgeportion of the base portion and an inward projection extending radiallyinward from an inner edge portion of the pieces; the outward projectionor the inward projection bends toward the penetrating portions; each ofthe penetrating portions includes a first penetrating portion and asecond penetrating portion with a narrower radial width than the firstpenetrating portion; and a bent portion of the outward projection or theinward protection is accommodated inside the first penetrating portion.9. The manufacturing method of the rotor core according to claim 8,further comprising making a thickness of the connecting portion in theaxial direction thinner than each of the base portion and the pieceportion.
 10. The manufacturing method of the rotor core according toclaim 9, wherein, in the making the thickness of the connecting portionin the axial direction thinner than each of the base portion and thepiece or the process of providing the notch in the connecting portion,press working is performed.
 11. The manufacturing method of the rotorcore according to claim 9, wherein, in the making the thickness of theconnecting portion in the axial direction thinner than each of the baseportion and the piece or the process of providing the notch in theconnecting portion, push back processing is performed.
 12. Themanufacturing method of the rotor core according to claim 8, furthercomprising providing a notch in the connecting portion.
 13. Amanufacturing method of a rotor using the rotor core manufactured by themanufacturing method of the rotor core according to claim 8, wherein amagnet is used as the cutter.
 14. The manufacturing method of the rotoraccording to claim 13, wherein the magnet is brought into contact withthe intervening portion in a final step of insertion into thepenetrating portion.
 15. A manufacturing method of a rotor using therotor core manufactured by the manufacturing method of the rotor coreaccording to claim 8, comprising a process of cutting the connectingportion with the cutter, and then removing the cutter from thepenetrating portion and inserting a magnet into the penetrating portion.